System for use in tissue repair

ABSTRACT

The present disclosure relates to a system for use in tissue repair. The system includes a cannulated guide, an obturator configured for insertion through the guide, a drill configured for insertion through the guide, and an anchor delivery tool configured for insertion through the guide.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. patent application Ser. No. 13/253,884 filed Oct. 5, 2011 which claims priority to U.S. Provisional Patent Application No. 61/390,239 filed Oct. 6, 2010, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND Field of Technology

The present disclosure relates to tissue repair and, more specifically, to a system for use in tissue repair.

Related Art

Medical devices and methods for attaching soft tissue to bone have been developed. Of particular interest, especially in sports medicine procedures, are suture anchors. A suture anchor is typically inserted into and fixed in a bore hole drilled into a bone at a surgical repair site. Sutures are typically coupled to the anchor and are used to secure the soft tissue to the bone in order to effect the repair. For many repair procedures, accuracy in the placement of suture anchors in bone is required to achieve consistently positive surgical outcomes, requiring substantial skill on the part of the surgeon.

Accurate placement of bore holes and suture anchors can be particularly challenging when repair is performed arthroscopically, as both access to and visibility of an arthroscopic surgical site may be more limited than is the case with open surgical procedures. For example, accurately drilling bore holes and placing suture anchors into these holes, at certain joint areas of the body, can be difficult for even a very experienced surgeon. This is due to the delivery devices not being able to reach a preferred anchor delivery point, not being able to achieve the preferred anchor trajectory, or both. In addition to these access and visualization problems, current devices used in the delivery of suture anchors cannot withstand the forces imposed by new techniques.

With the increasing popularity of arthroscopic repairs on the shoulder and hip, as well as repairs in other body joints including the ankle, knee, elbow, and foot, surgeons increasingly need to perform these procedures accurately and repeatably.

Accordingly, a need exists for devices and methods that provide for the accurate placement of suture anchors used in arthroscopic surgical procedures.

SUMMARY

The present disclosure relates to a system for use in tissue repair. The system includes a cannulated guide, an obturator configured for insertion through the guide, a drill configured for insertion through the guide, and an anchor delivery tool configured for insertion through the guide.

In an embodiment, the guide includes a handle and a shaft coupled to the handle. In another embodiment, the shaft includes a distal portion angled relative to a longitudinal axis of the shaft. In yet another embodiment, the distal portion includes at least one hole. In a further embodiment, the distal portion includes a plurality of holes. In yet a further embodiment, the distal portion includes an end having a serrated edge. In an embodiment, the obturator includes a handle and a shaft coupled to the handle. In another embodiment, the shaft includes a proximal portion, a distal portion, and a portion of reduced diameter located between the proximal portion and the distal portion. In yet another embodiment, the distal portion includes a blunt end. In a further embodiment, the distal portion includes a sharp end. In yet a further embodiment, the portion of reduced diameter is flexible relative to the proximal portion.

In an embodiment, the drill includes a proximal portion, a distal portion, and a flexible portion. In another embodiment, the proximal portion includes an end configured for coupling to a drill. In yet another embodiment, the proximal portion includes a depth stop. In a further embodiment, the proximal portion includes an area of reduced diameter. In yet a further embodiment, the area includes a laser mark. In an embodiment, the distal portion includes helical threads. In another embodiment, the distal portion includes a pointed end. In yet another embodiment, the distal portion includes a laser mark. In a further embodiment, the anchor delivery tool includes a handle and a shaft coupled to the handle. In yet a further embodiment, a distal portion of the shaft includes an area of reduced diameter and a tip extending from the distal portion. In an embodiment, the distal portion is flexible relative to the proximal portion.

Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present disclosure and together with the written description serve to explain the principles, characteristics, and features of the disclosure. In the drawings:

FIG. 1 shows an isometric view of the guide of the present disclosure.

FIG. 2 shows a side view of the guide of FIG. 1.

FIG. 3 shows an exploded view of the distal portion of the guide of FIG. 1.

FIG. 4 shows a side view of a first embodiment of the obturator of the present disclosure.

FIG. 5 shows an isometric view of a second embodiment of the obturator of the present disclosure.

FIG. 6 shows a side view of the obturator of FIG. 5.

FIG. 7 shows an exploded view of the distal portion of the obturator of FIG. 5.

FIG. 8 shows a side view of the drill of the present disclosure.

FIG. 9 shows an exploded view of the distal portion of the drill of FIG. 8.

FIG. 10 shows an exploded view of the area of reduced diameter of the drill of FIG. 8.

FIG. 11 shows an isometric view of the anchor delivery tool of the present disclosure.

FIG. 12 shows an exploded view of the distal portion of the anchor delivery tool of FIG. 11.

FIG. 13 shows a side view of the anchor delivery tool of the present disclosure.

FIG. 14 shows an exploded view of the distal portion of the anchor delivery tool of FIG. 13.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses.

FIGS. 1-3 show a guide 10. The guide 10 includes a cannulated handle 11 having a distal portion 11 a, a proximal portion 11 b, and an outer surface 11 c. The guide 10 also includes a shaft 12 coupled to the handle 11. The shaft 12 includes a proximal portion 12 a and distal portion 12 b. The proximal portion 12 a of the shaft 12 is coupled to the distal end 11 a of the handle 11. The distal portion 12 b of the shaft 12 is angled relative to a longitudinal axis L of the guide 10, which allows the surgeon to achieve the ideal insertion angle of the drill at a quicker rate, thereby reducing the potential of damage to cartilage and other tissue within the joint area, as will be further described below. The distal portion 12 b also includes at least one hole 12 b′. For the purposes of this disclosure, the distal portion 12 b includes a plurality of holes. The holes 12 b′ are used during surgery to view the tissue anchor and, specifically the orientation of the tissue anchor, prior to inserting the anchor into bone, as will be further described below. The holes 12 b′ may also be used to vent bone and other debris that may become located within the distal portion 12 b of the guide 12 during surgery, as will be further described below. An end 12 c of the shaft 12 includes a serrated edge 12 c′ for facilitating maintenance of the guide 10 on the bone during surgery, thereby substantially reducing slippage of the guide 10 off of the bone, as will be further described below. Rather than a serrated edge 12 c′, the end 12 c may have other features known to one of skill that would help in maintaining the guide 10 on the bone and reduce slippage.

For the purposes of this disclosure, the handle 11 is manufactured from polymer material and via a molding or machining process. The shaft 12 is manufactured from metal material, such as stainless steel, and the holes 12 b′ and serrated edge 12 c′ are machined onto the shaft 12. The distal portion 12 b of the guide 10 is bent or provided with an angle relative to the guide axis L via the use of a mandrel or other instrument that could be used to bend the shaft 12. Other material and processes for making the handle 11 and shaft 12 are also within the scope of this disclosure. The handle 11 and shaft 12 are coupled together via a press-fit procedure. However, other manners of coupling are also within the scope of this disclosure.

FIGS. 4-7 show embodiments of an obturator 20 for use with guide 10. The obturator 20 includes a handle 21 and a shaft 22 coupled to the handle 21. The shaft 22 includes a proximal portion 22 a coupled to the handle 21, a distal portion 22 b, and a portion 22 c located between the proximal and distal portions 22 a,22 b having a reduced diameter relative to the diameter of the proximal and distal portions 22 a,22 b. The reduced diameter of portion 22 c allows the portion 22 c to bend when the shaft 22 is inserted through the guide 10 and the portion 22 c is located within the angled distal portion 12 b. FIG. 4 shows a first embodiment of the obturator 20 including a distal portion 22 b having a tapered, blunt end 22 b′ and FIGS. 5-7 show a second obturator 20 including a distal portion 22 b having a sharp end 22 b′. When the shaft 22 of the obturator 20 is located within the guide 10, the end 22 b′ extends through end 12 c, thereby reducing the possibility of the shaft end 12 c, and especially the serrated edge 12 c′, from catching onto tissue as the guide 10 is inserted into the body, in the case of the obturator 20 having the blunt, tapered end 22 b′, and allowing for easier and quicker insertion of the guide 10 into the body, in the case of the obturator having the sharp end 22 b′, as will be further described below.

For the purposes of this disclosure, the handle 21 is made from polymer material and via a molding or machining process. The shaft 22 is made from metal and via a welding procedure. The proximal portion 22 a, distal portion 22 b, and portion 22 c are welded together to make the shaft 22. However, a one-piece shaft is within the scope of this disclosure. The surface features of the distal portion 22 b, blunt, taper or sharp, pointed features, are made via a machining process. Other material and processes for making the handle 21 and shaft 22 are also within the scope of this disclosure.

FIGS. 8-10 show a drill 30 for use with the guide 10. The drill 30 includes a proximal portion 30 a, a distal portion 30 b, and a flexible portion 30 c located between the proximal and distal portions 30 a,30 b. The proximal portion 30 a includes an end 30 d having flat portions 30 d′ configured for coupling to a drill 30, a depth stop 30 e having flat sides 30 e′ for maintaining a location of the drill 30 while the drill 30 is sitting on a surgeon tray or table prior to use by the surgeon, and an area of reduced diameter 30 f. The area 30 f includes a laser weld mark 30 g, the purpose of which will be described below. The flexible portion 30 c extends between the area 30 f and the distal portion 30 b. When the drill 30 is located within the guide 10, portion 30 c is located within the angled distal portion 12 b and is sufficiently flexible to bend along the angle of portion 12 b. The flexible portion 30 c includes an inner layer of spirally would metal wires and an outer layer of spirally would metal wires surrounding the inner layer. The inner layer also includes a through hole extending the length of the flexible portion 30 c. The distal portion 30 b includes helical threads 30 h, a pointed end 30 i, and a laser weld mark 30 j. When the drill 30 is located within the guide 10, the end 30 b extends through end 12 c, thereby allowing the user to drill a hole in bone during surgery, as will be further described below.

For the purposes of this disclosure, the drill 30 is made from metal, such as stainless steel. The flat portions 30 d′,30 e′ of the end 30 d and the depth stop 30 e may be machined onto the end 30 d and stop 30 e. The area of reduced diameter 30 f includes an inner wall having a diameter that is the same or similar to the diameter of the inner wall of the portion of the distal portion 30 b that is coupled to the flexible portion 30 c. The area of reduced diameter 30 f is made via a machining process.

The flexible portion 30 c is made via the use of a mandrel, which is removed from the through hole of the inner layer once the flexible portion 30 c is made. As mentioned above, the ends of the flexible portion 30 c are laser welded to the area 30 f and distal portion 30 b. The ends are inserted into the area 30 f and distal portion 30 b and then a laser is used to melt the metal material to the ends where the laser welds 30 g,30 j are located in FIGS. 9 and 10, thereby welding the area 30 f and the distal portion 30 b to the flexible portion 30 c. Coupling of the flexible portion 30 c to the area 30 f and distal portion 30 b in this manner reduces breakage or failure of the laser welds 30 g,30 j due to the laser welds 30 g,30 j being located in an area where there is the least amount of movement of the flexible portion 30 c during use of the drill 30.

During use of the drill 30, the depth stop 30 e abuts the handle 11, thereby substantially reducing over-insertion of the distal portion 30 b into the bone, as will be further described below. The threads 30 h and pointed end 30 i on the distal portion 30 b are made via a machining process. The drill 30 and its components and features may be made from other materials and processes known to one of skill in the art.

FIGS. 11-14 show an anchor delivery tool 40. The tool 40 includes a shaft 41 and a handle 42 coupled to the shaft 41. The shaft 41 includes a proximal portion 41 a and a distal portion 41 b. The distal portion 41 b, as more clearly shown in FIG. 12, includes an area of reduced diameter 43 and a tip 44 that extends from the distal portion 41 b. The area of reduced diameter 43 allows the shaft 41 to bend along the angled distal portion 12 c when the shaft 41 is inserted through the guide 10. Prior to use, a suture anchor (not shown) is coupled to the tip 44. The suture anchor (not shown) extends through end 12 c when the shaft 41 is disposed within the guide 10. The shaft 41 also includes grooves 41′ for housing of suture extending from the anchor, as will be further described below.

The proximal portion 41 a of the shaft 41 is coupled to the handle 42. The handle 42 includes a hub 42 a, a nose cone 48 coupled to the hub 42 a, and a knob 49 coupled to the hub 42 a and located between the nose cone 48 and the handle 42. The handle 42 further includes two suture retaining features 42 b, or tabs, for retaining suture during surgery, as will be further described below, laterally extending ribs 42 c for maintaining a grip on the handle 42 while imparting axial compression during surgery, and a through passage 42 d. The nose cone 48 includes a flat distal portion 48 a, and a proximal portion 48 b. In addition, the nose cone 48 includes a slotted opening 48 d for housing suture during surgery, as will be further described below, and a bore 48 e. The knob 49 also includes laterally extending wings 49 c.

The handle 42 and shaft 41, their components, and their method of use are more fully described in International Patent Application Publication WO 2009/023034 ('034 publication), which is incorporated herein by reference in its entirety. However, the area of reduced diameter 43 is made via a machining process or other process known to one of skill in the art. In addition, the suture anchor used with the device 40 and the manner in which it is used is the same suture anchor and method of use shown in the '034 publication.

The method of tissue repair via use of the system and its components is similar to the method of tissue repair shown and described in the '034 publication. The method includes inserting the obturator through the guide, inserting the guide/obturator combination into the joint area such that the end of the guide shaft is engaged with bone, removing the obturator, inserting the drill through the guide and operating the drill to create a hole in the bone, removing the drill, inserting the shaft of the delivery device through the guide and inserting the anchor into the hole and removing the guide and delivery device. Subsequent to removal of the guide and delivery device, the soft tissue is located adjacent to the suture anchor and the suture may be pulled through the tissue and subsequently tied to fixate the tissue to the bone.

As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the disclosure, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. 

What is claimed is:
 1. A system for use in tissue repair comprising: a cannulated guide; and a drill configured for insertion through the guide, the drill including a proximal portion, a distal portion, and a flexible portion therebetween; the drill distal portion including; a lumen having an opening at a proximal edge of the drill distal portion; helical threads; and a laser weld mark circumferentially disposed around an outer surface of the drill distal portion, coincident with a proximal edge of the helical threads and spaced away from the proximal edge of the drill distal portion, an end of the flexible portion extending within and attached to the lumen via the laser weld.
 2. The system of claim 1 wherein the drill proximal portion includes a depth stop and a cavity at a distal-most end and a proximal laser weld mark spaced away from the distal-most end, the flexible portion coupled to the cavity via the proximal laser weld.
 3. The system of claim 1 wherein the guide has a guide shaft including a distal portion angled relative to a longitudinal axis of the guide shaft.
 4. The system of claim 1 further comprising an obturator configured for insertion through the guide.
 5. The system of claim 1 further comprising an anchor delivery tool configured for insertion through the guide.
 6. A system for use in tissue repair comprising: a cannulated guide; and a drill configured for insertion through the guide, the drill including a flexible portion having first and second ends, the first end extending into a cavity of a drill proximal portion and the second end extending into a cavity of a drill distal tip; wherein the drill proximal portion has a proximal laser weld mark spaced away from a distal-most end of the drill proximal portion and wherein the drill distal tip has a distal laser weld mark spaced away from a proximal edge of the drill distal tip and coincident with a proximal edge of helical threads of the drill distal tip, and wherein the first and second ends of the flexible portion are coupled to the drill proximal portion and distal tip via laser welds associated with the proximal and distal laser weld marks respectively.
 7. The system of claim 6 wherein the guide has a guide shaft including a distal portion angled at a non-zero angle relative to a longitudinal axis of the guide shaft, and wherein the flexible portion is configured to bend along the non-zero angle.
 8. A system for use in tissue repair comprising: a cannulated guide; and a drill configured for insertion through the guide, the drill including a proximal portion, a distal portion, and a flexible portion disposed therebetween; wherein the drill proximal portion includes a depth stop at a first end, a cavity at a distal-most end and a first laser weld mark spaced away from the distal-most end; and wherein the drill distal portion includes a sleeve portion, helical threads, and a second laser weld mark spaced away from a proximal edge of the sleeve portion and disposed on a proximal edge of the helical threads; and wherein ends of the flexible portion extend within and are coupled to the cavity and the sleeve portion via first and second laser welds associated with the first and second laser weld marks respectively.
 9. The system of claim 8 wherein the guide has a guide shaft including a distal portion angled relative to a longitudinal axis of the guide shaft.
 10. The system of claim 9 wherein the distal portion of the guide shaft includes a plurality of holes axially spaced along a first side of the guide shaft.
 11. The system of claim 8 further comprising an obturator configured for insertion through the cannulated guide.
 12. The system of claim 11 wherein the obturator comprises a single piece shaft, including a proximal portion having a first length and a portion of reduced diameter extending from the proximal portion having a second length, the second length similar in length to the drill flexible portion.
 13. The system of claim 12 wherein the obturator shaft portion of reduced diameter is flexible relative to the obturator shaft proximal portion.
 14. The system of claim 8 further comprising an anchor delivery tool configured for insertion through the guide.
 15. The system of claim 8 wherein the flexible portion has an outer diameter that is smaller than an outer diameter of the proximal portion distal-most end and also smaller than an outer diameter of the sleeve portion.
 16. The system of claim 8 wherein the flexible portion includes an inner layer comprising a plurality of spirally wound metal wires, and an outer layer comprising a plurality of spirally wound metal wires surrounding the inner layer, and a through hole extending the length of the flexible portion.
 17. The system of claim 16 wherein the inner and outer layers of spirally wound metal wires extend within and are coupled to the proximal portion cavity and the distal portion sleeve portion of the drill via the first and second laser welds respectively. 